sta-rite basic training manual...circulation system p ool & spa basic training 1 s4247 3 5 swim. .....

Sta-Rite IndustriesBasic Training Manual

THIRD EDITION

Hydraulics

Pumps

Motors

Filtration

Heaters

© 2003 Sta-Rite Industries, Inc. Printed in USA S4247 (Rev. 9/03)

2668 0397NF

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Table of Contents

Pool & Spa Basic Training S4247

SECTION 1Hydraulics

Circulation System ...........................................................................................1Hydraulics Water Flow ....................................................................................2Friction Head Loss, Static Suction Lift, Elevation – Atmospheric Pressure .................................................................3Fittings and Valves – Friction Head Loss ....................................................4Pipe Sizing, Pipe, Friction Head Loss ............................................................5Exit Loss, System Head Loss ..........................................................................6Swimming Pool Gallons, Turnover Rate Gallons Per Minute (GPM)....................................................7Spa-Gallons Per MinuteSpa-Turnover RateSpa Jets-Gallons Per Minute Calculate System Head Loss............................................................................8Procedures for Calculating the Head Loss – Suction Side ........................9Procedures for Calculating the Head Loss – Return Side .......................10Spa Circulation SystemPlumbing, Spa Jet System Plumbing ...........................................................11Plumbing & Safety Tips .................................................................................12Friction/Flow Chart for Schedule 30 PVC Pipe ........................................13Exit Loss Charts ........................................................................................14, 15Friction Loss Created by Pipe Fittings ..................................................16, 17Calculating Turn Over Rates ........................................................................18

SECTION 2Pumps

Swimming Pool and Spa Pumps .................................................................19Impellers ..........................................................................................................20Water Flow .......................................................................................................21Head vs. Capacity ..........................................................................................22Semi Open Impeller Pump Test ....................................................................23Closed Impeller Pump Test............................................................................24Pump Curves – Sizing Pumps ......................................................................25Plumbing and Safety Tips ..............................................................................26

SECTION 3Motors

Swimming Pool and Spa Motors Principles of Operation ......................27Basic Component Parts ..................................................................................28Motor Name Plate ....................................................................................29, 30Motor Test ........................................................................................................31Electrical and Safety Tips ...............................................................................32Approximate Cost of Operating Electric Motors .......................................33Single Phase Wire Size Selection Charts......................................................34Pump Curve Graph.........................................................................................35Plumbing Tips ..................................................................................................36

SECTION 4Filtration

Swimming Pool, Spa and Water Feature Filtration ..................................37Diatomaceous Earth Filters ...........................................................................38D.E. Filter – Basic Operation

D.E. Substitues ..........................................................................................39Pre-Coating D.E. Filters

Velocity and its Effects on D.E. Filtration ............................................40Sizing a D.E. Filter...........................................................................................41Sand Filtration..................................................................................................42Sand Filter and Backwash Cycle...................................................................43Sand Filter Sizing.............................................................................................44Velocity and Sand Filtration ..........................................................................45Cartridge Filtration .........................................................................................46Basic Operation of a Sand Filter

Velocity and the Cartridge FilterVelocity and the Mega Cartridge Filter .................................................47

Cleaning the Cartridge ElementDual Filter SystemsSizing a Standard Cartridge Filter .........................................................48

Sizing a Mega Cartridge Filter ......................................................................49Backwash Valves..............................................................................................50Filtration and Safety Tips ...............................................................................51

SECTION 5Heaters

Swimming Pool and Spa Heaters ................................................................52Heat Loss .........................................................................................................53Natural Gas/Propane Heaters

Heater EfficienciesBasic Operations .......................................................................................54

Basic Heater Components..............................................................................55Gas Flow and Air Flow Through the Heater..............................................56Heater Sizing ....................................................................................................57Plumbing and Safety Tips ..............................................................................58

SECTION 6Reference

Basic Spa Equipment and Piping Specifications .......................................59Spa Jet Hydraulics ..........................................................................................60Basic Swimming Pool Worksheet ................................................................61

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10. Filter9. Backwash Valve

5. Depth Marker 16. Recessed Steps4. Underwater Light 15. Cup Anchor

13. Safety Check Valve

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Figure 1

1 SECTION Hydraulics

Pool & Spa Basic Training 2 S4247


HydraulicsHydraulics, as used in this text, deals with the physicalmovement of water for the many purposes associated withswimming pools, spas, and water features.

These purposes include the following:

• Passing the water through a filter to remove the sus-pended particles.

• Moving the water through a heater, solar system orother device for the purpose of raising or lowering thewater temperature. (1)

• Providing enough flow of water with the right amountof force to operate a pool cleaner or cleaning system.

• Delivering the right amount of water flow to operateseveral therapy jets for spas.

• Supplying water flow to sanitizing devices such as chlo-rinators, brominators, and ozone generators.

• Providing the right flow for the many types of foun-tains, water falls, water slides, wave pools, and otherspecialty applications used with pools and spas.

(1) In many very hot areas of the world, solar systems are used atnight to lower the temperature of the water.

In order to move water for the above purposes, we mustexamine how we make it flow efficiently. We need to knowwhat restricts flow and how to calculate the resistance.Once we understand flow and resistance, we can overcomethese obstacles to deliver the desired results. This is thepurpose of the section on hydraulics.

Water FlowWater flows naturally downhill. Unfortunately, we can’tdesign a swimming pool, spa, or water feature so that thewater is always following gravity. To provide water flowfor all the different tasks associated with a pool, spa, orwater feature, we use a pump. The pump, which will bediscussed in Section II, draws and pushes the waterthrough pipes, fittings, filters, heaters, etc., used in theoperation of a pool, spa, or water feature. These objects create resistance to flow that the pump must overcome.

Examine the basic pool plumbing layouts in Figures 1 and2. List the objects that cause the resistance the pump mustovercome to deliver the proper amount of flow.

____________________________________________________

____________________________________________________

____________________________________________________

Figure 2

RESISTANCE



Friction Head LossThe resistance to flow (Friction Head Loss) is expressed inFEET OF HEAD. For example, see Figure 3: Water flowingat 40 GPM (gallons per minute) through a 2” skimmer willresult in 2 ft. of head loss. 75 GPM through a 53 sq. ft. D.E.will result in 7.0 ft of head loss.

Static Suction LiftThe vertical distance between the center line of the pumpimpeller and the surface level of the water is called thestatic suction lift. This distance can be expressed as PositiveSuction Head or Negative Suction Head. Both areexpressed as Feet of Head.

1. Positive Suction Head – Pump is located below the sur-face of the water. This can be a standard centrifugal or aself-priming centrifugal pump.

2. Negative Suction Head – Pump is located above the sur-face of the water. This type of pump is usually consid-ered a “Self Priming Pump”.

Example:A pump located 5’ above the surface of the waterwill add 5 ft. of head loss to the system. (Figure 4)

A pump located 5 ft. below the surface of thewater will reduce system head loss by 5 feet. This isdue to the weight of the water assisting the pump.

Elevation - Atmospheric PressureAtmospheric pressure on the surface of the water helps aself-priming centrifugal pump to perform. The higher theelevation that the pump is installed, the pressure on thesurface of the water decreases. This decrease reduces theamount of work a given pump can do.

Example:The ability of a pump to lift water is reduced by1.155 ft. of head for every 1,000 ft. of elevation.

A pump that lifts water 10 ft. at sea level will onlybe able to lift water 8.845 ft. at an elevation of1,000 ft. At 5,000 ft. of elevation, that same pumpwill only be able to lift water 4.225 ft., or in otherwords, a reduction of over 50% in the pump’scapacity to lift.

5'

Figure 3 Figure 4

HEAD LOSS

See Charts & TablesPage 17 for

Head Loss Charts forother equipment.

The water is belowcenterline of pump

STATIC SUCTION LIFT

SKIMMER

40 GPM

75 GPM

2 FT.

7 FT.Head Loss

FILTER

5’



Fittings And Valves - Friction Head LossWhen water flows through fittings and valves, turbulenceis created in the water, which can result in cavitation. Thesetwo phenomena produce a significant amount of frictionhead loss. (See Figure 5).

Important Note: Unlike filters, heaters, skimmers, etc., wedo not express the resistance in fittings and valves as headin feet. Instead, it is stated as “EQUIVALENT LENGTHOF STRAIGHT PIPE.”

Example:One 2” 90° PVC elbow is expressed as 8.5 ft. of 2”pipe. A sweep 2” PVC 90° is expressed as 3.6 ft. of2” pipe. (See Figure 6)

Why is a sweep 90° equivalent to a shorter lengthof pipe than a 90° elbow?

____________________________________________

____________________________________________

What is the difference in friction head loss betweena Branch Flow Tee and a Line Flow Tee?

____________________________________________

____________________________________________

Using the Charts and Tables Manual, Pages 36 & 37, com-plete the following chart. (Use the Screwed/Steel numbers.They are equivalent to PVC pipe.)

What is the equivalent length of pipe?

1 - 11⁄2” 90° elbow_____________________________________

1 - 3” branch flow tee_________________________________

1 - 11⁄2” globe valve ___________________________________

2 - 2” 45° elbows _____________________________________

4 - 11⁄2” gate valves____________________________________

1 - 3” line flow tee____________________________________

How much less equivalent length of pipe are 2 45° elbowsthan 1 90° elbow?______________________________________________________

Now compare one sweep 11⁄2” 90° with two 11⁄2” 45° elbows.______________________________________________________

Calculate the equivalent length of pipe savings in a plumb-ing layout that was designed with ten 2” regular 90° ellsthat will be replaced with twenty 2” 45° ells.

Ten 2” 90° regular ells = __________ft.

-Twenty 2” 45° ells = __________ft.

Equivalent Length of Pipe Savings =__________ft.

Figure 6Figure 5

FITTINGS & VALVESFRICTION HEAD LOSS

EQUIVALENT LENGTHOF STRAIGHT PIPE

90°ELBOW

GLOBEVALVE

1-1/2”TEE

2” 90°

Line Flow = 5.6’Branch Flow = 9.9’

Short Radius = 8.5’Long Radius = 3.6’



Pipe SizingThere are other factors that can cause resistance in theplumbing system. The major factor affecting the efficiencyof water flow is VELOCITY.

Velocity is a term used to express the speed at which theflow of water travels through a pipe and fittings. Thevelocity of the water is measured and expressed in feet persecond (FPS).

The velocity of water flowing through a pipe and fittings isdetermined by two factors:

1. The volume or quantity of flow (GPM).

2. The size of the pipe through which the water is moving.

As water flows through the pipe (Figure 7), it encountersfriction from the pipe walls. The faster the water moves,the more friction it encounters. In fact, if we double theflow in a given pipe, the velocity will double, and frictionloss will increase approximately 4 times.

Pipe - Friction Head LossAs you see in the Friction Flow Chart for 11⁄2” schedule 40PVC pipe (Figure 8), 40 GPM travels at a speed of 6.30 FPSthrough the 11⁄2” pipe. At this speed, the amount of frictionloss will be 8.9 ft. of head for each 100 ft. Length of pipe.

If the flow were doubled to 80 GPM through the same 11⁄2”pipe, the speed of the water doubles to 12.60 FPS.However, and more important, the friction head lossincreases almost 4 times to 35 feet of head.

Due to the rapid increase in friction head loss as the flowincreases in a given pipe, we follow the recommendationsof the Hydraulic Institute for suction pipe sizing.

Schedule 40 PVC pipe .................................velocity is 7 FPS

Copper Pipes ..................................................velocity is 6 FPS

Polyethylene Coil Pipe ................................velocity is 5 FPS

Using the Charts and Tables, Page 29, determine as closelyas possible the flow (GPM) at or near 7 FPS for each of thefollowing Sched. 40 PVC pipe.

3/4” _____________ 1 “ ______________ 11⁄4” _____________

11⁄2 “ _____________ 2 “ ______________ 21⁄2” _____________

3” __________ 4” __________ 6” __________ 8”__________

Figure 8Figure 7

FRICTION LOSS - PIPE FRICTION FLOW CHART1-1/2” PVC Pipe (100 ft. lengh)

VELOCITY7 FPS

FRICTIONVELOCITY HEAD

GPM (FPS) (FT.)

20 3.15 2.47

40 6.30 8.90

80 12.60 35.00

160 25.20 140.00



Exit LossExit loss occurs on the “discharge” side of the pool, spa, orwater feature’s circulation system, also know as the “returnside”. This loss occurs as a result of the water being dis-charged from the orifices in the return inlets fittings intothe large body of water.

The resistance created by the exit loss is calculated asVelocity Head Loss in Feet. This exit head loss is part of thetotal head loss on the discharge side of the pump. Exit LossCharts are provided in the Charts and Tables, Page 18.

NOTE: An important thing to remember is that this resis-tance is not cumulative. You only add the head loss onetime, regardless of the number of return fittings.

Example:A pool with three 1” return lines, each moving 20GPM, will add 1.04 ft. of head to the dischargehead loss. (The head for one fitting only)

Using the chart on Page 18 of the Charts and Tables, fill inthe following Exit Head Losses.

Five 3/4” return lines flowing 15 GPM each willadd________ft. of head to the discharge head loss.

Two 3/8” return lines flowing 10 GPM each willadd________ft. of head to the discharge head loss.(See Figure 9).

System Head Loss orTotal Dynamic Head Loss (TDH)As we have read in previous pages, many things contributeto the resistance to flow that the pump must overcome.Skimmers, main drains, fittings, pipe size, velocity, heaters,filters, automatic cleaning systems, and elevations are someof these obstacles. We know that these factors have resis-tance values that can be calculated. Once calculated andcombined they are known as the Total System Head Lossor TDH (Total Dynamic Head).

We now can begin calculating the System Head Loss. Thesteps necessary are as follows:

1. DETERMINE THE REQUIRED FLOW RATE

There are several steps we must follow to calculate theflow rate. Two factors are necessary for any body of water.

A. How many gallons are we dealing with?

B. What is the desired turnover rate?

A. SWIMMING POOL GALLONS

It is a simple matter to calculate the gallonage of a squareor rectangle swimming pool. Free formed pools, such asovals and kidney shapes are much more difficult. Page 40of the Charts and Tables shows some additional formulasfor free formed pool.

Figure 9

EXIT LOSS

FROM JET PUMP

FROMCIRCULATION SYSTEM

5 - 3/4” RETURNS@ 15 GPM EACH

2 - 3/8” RETURNS@ 10 GPM EACH

Note:“Only useLossOne time”



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A. Swimming Pool GallonsFigure 10 is a rectangle shaped swimming pool. To calcu-late the amount of water in the swimming pool, the firststep is to determine the square feet of surface area.

Length x Width = surface area square footage.

The second step is to find the average depth. (AD) This isaccomplished by taking at least 2 measurements. One atthe shallow end and the other at the deepest point of thepool.

3 feet + 7 feet = 10 feet/ 2 = a AD of 5 feet.

The Third step is to multiply the square footage times theaverage depth to get cubic feet.

sq. ft. x AD = cubic feet

The final step is to multiply the cubic feet by 7.48 ( Thenumber of gallons in a cubic foot)

Cubic Feet x 7.48 = gallons

Example:Calculate the gallons for the swimming pool inFigure 10.

Length_____x ____Width_____x AD_____x 7.48

Equals______Gallons.

B.Turnover RateEach time the total volume of water in a swimming pool,spa or water feature is passed through the filter, it is said tohave “turned over” once. Although the “turnover rate”should be the number times that a complete turnoveroccurs in 24 hours, we usually talk about the number ofhours it takes to turn over the water once.

Example:A body of water passing through a filter 3 times in24 hours is considered to have an “8-hour turnover”.

If 4 “turns” are required in 24 hours, then a “6-hour turnover” is required.

If a “12-hour turnover” is needed, then all thewater will pass through the filter twice in 24 hours.

Gallons Per Minute (GPM)To determine the GPM, we divide the total body of waterby the number of minutes in the turnover hours.

Example:A 30,000 gallon pool with an 8 hour turnover:

30,000 / 480 (8 X 60) = 62.5 GPM

What is the GPM for a 30,000 gallon pool with a 6-hour turnover?__________

Figure 10

SWIMMING POOL GALLONS

Gallons = L x W x AD x 7.48

3’

8’

18’

36’



Spa - Gallons Per MinuteAnd Turnover RatesSince we usually deal with a small volume of water, thegallons per minute for the turnover rate is not normallycalculated. However, commercial installations may require15 minute turnovers. The calculation is the same as for aswimming pool.

Gallons/15 minutes = GPM.

Example:A 30 minute turnover for a 400 gallon spa is13.4 GPM. A 1 hour turnover for a 600 gallon spais 10 GPM. Calculate the GPM for the followingspas:

1,000 gallons with a 30 minute turnover rate:

________GPM.

800 Gallons with a 11⁄2 hour turnover rate:

________GPM.

Spa Jets - Gallons Per MinuteSpa jets are the main factor in calculating the necessary gal-lons per minute. In the old days, we could figure 1/4 HPper jet. At that time, most jets required 20 GPM each. Withimprovements in jet design and pump performance, wemust know the jet’s required GPM.

If the jet is rated at 15 GPM and there are 6 of them, wesimply multiply the two together to get the gallons perminute (15 GPM x 6 = 90 GPM)

Because of the many different types of jets available on themarket today, it is a good idea to consult with the jet man-ufacturer before calculating the necessary GPM requiredfor the system.

Calculate Friction Head LossFigure 11 shows a short plumbing section on the dischargeside of the pump.

There is 100 ft. of 2” PVC pipe with 10 - 2” regular 90° ells,flowing 75 gallons per minute.

The procedure for calculating the head loss in the aboveplumbing layout is as follows: (Refer to Pages 29, 36, and37 for conversion charts in the (Charts and Tables).

1. Convert the 2” 90 ells to equivalent length of pipe.

2. Add the equivalent length of pipe to the existing lengthof pipe.

3. Divide the total equivalent length of pipe by 100.

4. Find the friction loss for 75 GPM through 2”pipe.

5. Multiply the friction head loss times the equivalentlength of pipe to get the total friction head loss.

Figure 11

Discharge Side100’ of 2” PVC pipewith 10 regular2” 90° ells

1. (10) 2” 90° ells = 85’2. 85’ + 100’ = 185’3. Divided by 100 = 1.85’4. Friction Loss @ 75 GPM

through 2” PVC = 7.2’5. Total Loss = 1.85’ x 7.2’ =

13.32 feet of friction head loss

Suction SideVacuum = 10”10” x 1.13 = 11.3’

50 ft. in Head

75 GPM 7 FPS



8��5'

Skimmer Line:1. Convert the fittings to equivalent

length of pipe.3 - 2” Reg. 90° Ells = 3 x 8.5 = 25.5’1 - 2” Gate Valve = 1.5’Total equivalent lengthof pipe = 27.0’

2. Add equivalent length of pipe to theactual pipe length.Equivalent length of pipe = 27.0’Length of 2” pipe = 40.0’Total pipe length = 67.0’

3. Convert total pipe length to 100’length.67.0’ / 100 = .67’

4. Calculate the Friction Head Loss in theSkimmer Line.67’ pipe length x 2.35 = 1.57’1 - 2” Skimmer @ 37.5 GPM = 1.75’Total Friction Head Loss = 3.32’

Main Drain Line:1. Convert the fittings to equivalent

length of pipe.1 - 2” Branch Flow Tee = 12.00’3 - 2” Reg. 90° Ell = 3 x 8.5 = 25.50’1 - 2” Gate Valve = 1.50’Total equivalent lengthof pipe = 39.00’

2. Add equivalent length of pipe toactual pipe length.Equivalent length of pipe = 39.00’Length of 2” pipe = 65.00’Total pipe length = 104.00’

3. Convert total pipe length to 100’length.104.00’ / 100 = 1.04’

4. Calculate the Friction Head Loss in theMain Drain Line.1.04’ pipe length x 2.35 = 2.44’2 - 2” M.D. @ 37.5 GPM = 2.00’Total Friction Head Loss = 4.44’

Manifold Line:1. Convert the fittings to equivalent

length of pipe.1 - 2” Regular 90° Ell = 8.50’1 - 2” Branch Flow Tee = 12.00’Total equivalent lengthof pipe = 20.50’

2. Add equivalent length of pipeto the actual pipe length.Equivalent length of pipe = 20.50’Length of 2” pipe = 4.00’Total pipe length = 24.50’

3. Convert total pipe length to 100’length.24.50’ / 100 = .25’

4. Calculate the Friction Head Lossin the Manifold Line..25’ pipe length x 7.17 = 1.79’Total Friction Head Loss = 1.79’

Suction Side Head Loss:Skimmer Line = 3.32’Main Drain Line = 4.44’Manifold Line = 1.79’Static Suction Lift = 5.00’Total Suction Head Loss = 14.55’

Figure 12

SUCTION SIDE PLUMBING

StaticSuction Lift

75 GPM

37.5 GPMEACHLINE

5’

Skimmer Line40’ 2” PVC Pipe3 2” 90° Ells1 2” Gate Valve

1 2” Skimmer

Main Drain Line65’ 2” PVC Pipe3 2” 90° Ells1 2” Gate Valve

2 2” Main Drains

1 2” Branch Flow Tee

Manifold Line4’ 2” PVC Pipe1 2” 90° Ell

1 2” Branch Flow Tee

Figure 12 is a typical plumbing layout for the suction side of the circulation system. In this example theSkimmer and Main Drain have separate lines manifolded together into the suction side of the pump.

Procedures for Calculating the Head Loss:(Refer to Charts on Pages 29, 36, and 37 of the Charts and Tables).



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Equipment Pad:1. Convert the fittings to equivalent

length of pipe.6 - 2” Reg. 90° Ells = 6 x ____ = ____1 - 2” Branch Flow Tee = ____Total equivalent lengthof pipe = ____

2. Add equivalent length of pipe to theactual pipe length.Equivalent length of pipe = ____Length of 2” pipe = ____Total pipe length = ____

3. Convert total pipe length to 100’length.Total pipe length ____ / 100 = ____

4. Calculate the Friction Head Loss in theequipment pad plumbing.100’ pipe length ____ x ____ = ____

5. Filter Head Loss = ____

6. Heater Head Loss = ____

7. Total Equipment PadHead Loss = ____

11⁄2” 50 GPM Line:1. Convert the fittings to equivalent

length of pipe.1 - 11⁄2” Reg. 90° Ell = ____1 - 11⁄2” Branch Flow Tee = ____Total equivalent lengthof pipe = ____

2. Add equivalent length of pipe to theactual pipe length.Equivalent length of pipe = ____Length of 11⁄2” pipe = ____Total pipe length = ____


4. Calculate the Friction Head Loss in the11⁄2” 50 GPM line.100’ pipe length ____ x ____ = ____

5. Friction Head Loss in 1” line = 9.0”(Including the Branch Flow Tee)

6. Exit Loss 3/4” @ 25 GPM = ____

7. Total Friction Head Loss = ____

11⁄2” 25 GPM Line:1. Convert the fittings to equivalent

length of pipe.2 - 11⁄2” Reg. 90° Ells = 2 x ___ = ____

2. Add equivalent length of pipe to theactual pipe length.Equivalent length of pipe = ____Length of 11⁄2” pipe = ____


4. Calculate the Friction Head Loss in the11⁄2” 25 GPM Line.100’ pipe length ____ x ____ = ____

Return Side Head Loss:Equipment Pad Head Loss = ____50 GPM Line Head Loss = ____25 GPM Line Head Loss = ____Total Return Side Head Loss = ____Total Suction Side Head Loss = ____Total Circulation SystemHead Loss = ____

Figure 13

FRICTION HEAD LOSS - RETURN SIDE OF PUMP

2”,75 GPM

11⁄2”,50 GPM

1” FrictionHead Loss = 9’

11⁄2” 50 GPM Line35’ 11⁄2” PVC Pipe3 11⁄2” Reg. 90° Ells1 11⁄2” Branch Flow Tee2 3/4” Eye Ball Fittings20’ 1” PVC Pipe2 1” Reg. 90° Ells

Equipment Pad32’ 2” PVC Pipe6 2” 90° Ells1 2” Branch Flow Tee300 Sq. Ft. Cart. Filter400,000 BTU Heater

11⁄2” 25 GPM Line15’ 11⁄2” PVC Pipe2 11⁄2” Reg. 90° Ells1 3/4” Eye Ball Fittings

11⁄2”,25GPM

Figure 13 is a typical plumbing layout for multiple return lines. One 2” line Teed into two 11⁄2” lines, onewith a single return fitting, the other with two return fittings.

Procedures for Calculating the Head Loss:(Refer to Charts on Pages 29, 36, and 37 of the Charts and Tables).



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Circulation System Plumbing:1. Surface Skimmer - Normal flow is a minimum of 25

gpm. The maximum flow is 50 gpm. Some skimmers aredesigned so that the Hair Lint Basket can be removedthrough the throat of the skimmer. Others are designedwith a built in Cartridge Filter. These are usuallyportable units that have a built in pumping, filteringand heating system.

2. Auxiliary Suction - Designed to offer a separate sourceof water for the pump in case the flow through the MainDrain or Skimmer become restricted. Auxiliary SuctionFitting should be IAPMO approved.

3. Main Drain - Located at the lowest point of the spa. It isdesigned to collect the heavier dirt particles that arepassed on to the filter system. The Main Drain Covershould be IAPMO approved. Always secure the coverwith a screw.

4. Deep Heat Return - By injecting heated water at thelowest point possible, you get a better distribution ofthe heat. This will make the heat up time more efficientand less costly.

Jet System Plumbing:5. Dual Main Drains - Designed for safety. By drawing the

water from two separate sources, the spa is safer frompossible entrapment and entanglement. Dual MainDrains also cut down on the possibility of eddies form-ing.

6. Spa Jets - Designed to add velocity to the water flowand draw air from the atmosphere or a MechanicalBlower. The addition of air can add as much as 50% tothe volume of the jet stream. There are some specializedjets on the market that give a messaging action. Theplumbing should be “Looped” for equal jet pressure.

7. Air Line - Usually a Flex type pipe. This line should be“Looped” for equal pressure and better distribution ofthe air.

8. Air Intake - Source for air for the spa jets. Can be con-nected to a Mechanical Blower for even better action.Some spas have a separate air line for each jet for indi-vidual adjustments.

Figure 14

TWO PUMP SPA SYSTEM

CIRCULATION SYSTEM

1

23

4

6

5

7 8

TO CIRCULATIONPUMP

FROMCIRCULATION SYSTEM

TO JET PUMP

FROM JET PUMP

JET SYSTEM



Plumbing & Safety Tips:1. Long Plumbing Runs - Always use the correct size

pump and compensate for extended pipe runs withlarger pipe sizes. Increasing pump H.P. to try to over-come long plumbing runs will make the system less effi-cient.

2. Dual Suctions - Dual suctions should be plumbed intoall pools and spas to prevent body or hair entrapment.Use only IAPMO approved fittings for suction use.

Areas to also consider for dual suctions are any shallowbody of water, such as a spa, fountain, or a wading pool.Dual suctions in shallow bodies of water will cut downon the possibility of “Eddies” forming. Eddies can causedamage to the pump and make the system less efficient.

In commercial Skimmer applications it is a good idea touse “Dual Auxiliary Suction Fittings to cut down on thevelocity of the water when the Auxiliary line is open.

3. Suction Connections for Suction Side Cleaners - Sidewall connections for the Suction Side Cleaners shouldhave a solid connection or Self Closing Sealing Coversshould be used on designated Suction Cleaner connec-tion, for safety. Friction connections may come looseexposing a single suction source that could trap some-one.

4. Pressure Testing Systems - Make sure to evacuate all ofthe air out of the system as the pressure builds. Trappedair will compress and powerfully propel a filter lid thathas an improperly installed clamp. Never pressure testwith pressures above 25 psi.

5. If you can’t “LOOP” your return fittings, tie into a cen-ter point with an equal number on each side of tee. Thenuse a tee on the last return instead of a 90°ell. Extendeach line about 6” to a foot past the tee and cap theends. The back pressure from the capped end will helpthe last fittings in the line to work better. It’s not as gooda looping, but it helps.

Figure 15

PLUMBING AND SAFETY TIPS

1"

1"

2"

1”

1”

2”

Multiple Lines vs.One Line

2 - 1” pipes can onlyhandle 1/2 the volume of a 2” pipe.

Pipe Sizing PerHorsepower of Pump(Self Priming @ 60’)

Equivalent Length of Pipe

Regular 2”90° Ell = 8.5’

Sweep 2”90° Ell = 3.6’

2 -2” 45°Ells - 5.4”

25’ Run 50’ Run Over 50’H.P. Suc. Ret. Suc. Ret. Suc. Ret.

1/2 1.5” 1.5” 1.5” 1.5” 2” 1.5”3/4 2” 1.5” 2” 2” 2” 2”1 2” 2” 2.5” 2” 2.5” 2.5”

1.5 2.5” 2.5” 3” 2.5” 3” 3”2 2.5” 2.5” 3” 3” 3” 3”3 3” 3” 3” 3” 4” 3”5 4” 3” 4” 4” 4” 4”

7.5 6” 6” 6” 6” 6” 6”10 6” 6” 6” 6” 6” 6”15 6” 6” 8” 6” 8” 8”20 8” 8” 8” 8” 8” 8”



U.S.3⁄4” Pipe 1” Pipe 11⁄4” Pipe 11⁄2” Pipe 2” Pipe 21⁄2” Pipe 3” Pipe U.S.

Gals. Vel. Loss Vel. Loss Vel. Loss Vel. Loss Vel. Loss Vel. Loss Vel. Loss Gals.per Ft. per in Ft. per in Ft. per in Ft. per in Ft. per in Ft. per in Ft. per in perMin. Sec. Feet Sec. Feet Sec. Feet Sec. Feet Sec. Feet Sec. Feet Sec. Feet Min.

1 .60 .25 .37 .07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.20 .90 .74 .28 .43 .07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.80 1.92 1.11 .60 .64 .16 .47 .07 . . . . . . . . . . . . . . . . . . . . . . . . 34 2.41 3.28 1.48 1.02 .86 .25 .63 .12 . . . . . . . . . . . . . . . . . . . . . . . . 45 3.01 5.8 1.86 1.52 1.07 .39 .79 .18 . . . . . . . . . . . . . . . . . . . . . . . . 56 3.61 7.0 2.33 2.15 1.29 .55 .95 .25 .57 .07 . . . . . . . . . . . . . . . . 68 4.81 11.8 2.97 3.6 1.72 .97 1.25 .46 .76 .14 .54 .05 . . . . . . . . 8

10 6.02 17.9 3.71 5.5 2.15 1.46 1.58 .69 .96 .21 .67 .09 . . . . . . . . 1015 9.02 37.8 5.57 11.7 3.22 3.07 2.36 1.45 1.43 .44 1.01 .18 .65 .07 1520 . . . . . . . . 7.42 19.9 4.29 4.2 3.15 2.47 1.91 .74 1.34 .30 .87 .12 2025 . . . . . . . . 9.28 30.0 5.36 7.9 3.94 3.8 2.39 1.11 1.67 .46 1.08 .16 2530 . . . . . . . . 11.14 42.0 6.43 11.1 4.73 5.2 2.87 1.55 2.01 .65 1.30 .23 3035 . . . . . . . . . . . . . . . . 7.51 14.7 5.52 7.0 3.35 2.06 2.35 .88 1.52 .30 3540 . . . . . . . . . . . . . . . . 8.58 18.9 6.30 8.9 3.82 2.63 2.64 1.11 1.73 .39 4045 . . . . . . . . . . . . . . . . 9.65 23.5 7.09 11.1 4.30 3.28 3.01 1.39 1.95 .48 4550 . . . . . . . . . . . . . . . . 10.72 28.5 7.88 13.5 4.78 4.0 3.35 1.69 2.17 .58 5060 . . . . . . . . . . . . . . . . . . . . . . . . 9.46 18.9 5.74 5.6 4.02 2.36 2.60 .81 6070 . . . . . . . . . . . . . . . . . . . . . . . . 11.03 25.1 6.69 7.4 4.69 3.14 3.04 1.09 7080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.65 9.5 5.35 4.0 3.47 1.39 8090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.60 11.8 6.03 5.0 3.91 1.73 90

100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.56 14.4 6.70 6.1 4.34 2.10 100125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 21.8 8.38 9.2 5.42 3.19 125150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.05 12.8 6.51 4.5 150175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.59 5.9 175200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.68 7.9 200225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.76 9.4 225250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.85 11.5 250275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Friction/Flow Chart For Schedule 40 Rigid PVC PipeFriction Loss of Water in Feet per 100 Feet Length of Pipe

Based on Williams & Hazen Formula Using Constant 150. Sizes of Standard Pipe in Inches.

Normal safe operating selection; ■■ Suction piping; ■■ Discharge or pressure piping.Note: Where long pipe runs are encountered, make selection in minimum head loss range.



Head Loss ChartsComponent GPM Head Loss (Ft.) Component GPM Head Loss (Ft.)

Main drain 20 0.5 Skimmer 20 1.01-1/2” 30 1.0 1-1/2” 30 2.0Outlet 40 1.5 40 3.0

50 2.0 50 4.060 2.5 60 5.5

Main drain 40 1.0 Skimmer 20 0.52” 50 1.5 2” 30 1.0

Outlet 60 2.0 Outlet 40 2.070 3.0 50 3.080 4.0 60 4.0

70 5.0Heater – 7.0 Average 80 6.0

Backwash Valves

1-1/2” Push/Pull 50 6.0 1-1/2” Multiport 50 5.075 13.5 75 10.0

2” Push/Pull 75 7.0 2” Multiport 75 3.5120 17.6 100 6.0

120 8.5

Cartridge Filters GPM (.75) Head Loss (Ft.) GPM (.375) Head Loss (Ft.)

25 sq. ft. 18.75 1.1 9.38 7.0 Average35 sq. ft. 26.25 2.0 13.13 7.0 Average50 sq. ft. 37.50 4.3 18.75 7.0 Average70 sq. ft. 52.50 7.5 26.25 7.0 Average75 sq. ft. 56.25 8.0 28.13 7.0 Average100 sq. ft. 75.00 17.5 37.50 7.0 Average135 sq. ft. 101.25 28.0 50.63 7.0 Average

Sand Filters GPM (20) Head Loss (Ft.) GPM (15) Head Loss (Ft.)

14” 1.05 sq. ft. 21.0 10 (est.) 15.8 7.0 Average16” 1.41 sq. ft. 28.2 12 (est.) 21.2 7.0 Average18” 1.80 sq. ft. 36.0 14 (est.) 27.0 7.0 Average20” 2.20 sq. ft. 44.0 16 33.0 7.0 Average22” 2.66 sq. ft. 53.2 18 (est.) 39.9 7.0 Average24” 3.10 sq. ft. 63.0 25 46.5 7.0 Average30” 4.90 sq. ft. 98.0 17 73.5 7.0 Average36” 7.10 sq. ft. 142.0 24 (est.) 106.5 7.0 Average

Modular Media Filters GPM Head Loss (Ft.) GPM (.375) Head Loss (Ft.)

100 sq. ft. “Mini Mods.” 75 6.0 38 1.5125 sq. ft. “Mini Mods.” 94 9.0 47 2.5150 sq. ft. “Mini Mods.” 113 12.0 56 3.5175 sq. ft. “Mini Mods.” 131 16.0 66 4.5200 sq. ft. “Mini Mods.” 150 20.0 75 6.0300 sq. ft. “Mini Mods.” 150 20.0 113 13.0

Modular D.E. Filters GPM (1.5) Head Loss (Ft.) GPM (NSF) Head Loss (Ft.)

30 sq. ft. 45 3.8 60 6.536 sq. ft. 54 5.5 70 9.060 sq. ft. 90 7.0 120 13.072 sq. ft. 108 10.0 144 18.0

Modular Media Filters GPM (NSF) Head Loss (Ft.)

300 sq. ft. - System3 100 3.0400 sq. ft. - System3 115 4.6450 sq. ft. - System3 124 5.5500 sq. ft. - System3 130 6.3



1.0” (1.0 ID)

Velocity Exit Head Velocity Exit Head Velocity Exit HeadGPM FPS (Ft.) GPM FPS (Ft.) GPM FPS (Ft.)

15 6.13 .58 27 11.03 1.89 39 15.93 3.9516 6.54 .66 28 11.44 2.03 40 16.34 4.1517 6.95 .75 29 11.85 2.18 41 16.75 4.3618 7.35 .84 30 12.26 2.34 42 17.16 4.5819 7.76 .94 31 12.66 2.49 43 17.57 4.8020 8.17 1.04 32 13.07 2.66 44 17.98 5.0221 8.58 1.14 33 13.48 2.83 45 18.38 5.2522 8.99 1.26 34 13.89 3.00 46 18.79 5.4923 9.40 1.37 35 14.30 3.18 47 19.20 5.7324 9.81 1.50 36 14.71 3.36 48 19.61 5.9825 10.21 1.62 37 15.12 3.55 49 20.02 6.2326 10.62 1.75 38 15.52 3.75 50 20.43 6.49

3/8” (.375 ID)

Velocity Exit HeadGPM FPS (Ft.)

1 2.91 .132 5.81 .533 8.71 1.184 11.62 2.105 14.53 3.286 17.43 4.727 20.34 6.438 23.24 8.409 26.15 10.63

10 29.05 13.12

1/2” (.50 ID)


5 8.17 1.046 9.80 1.497 11.44 2.038 13.07 2.669 14.71 3.36

10 16.34 4.1511 17.98 5.0212 19.61 5.9813 21.24 7.0214 22.88 8.1415 24.51 9.3416 26.15 10.6317 27.78 12.0018 29.41 13.4519 31.05 14.9920 32.68 16.61

3/4” (.75 ID)


5 3.63 .216 4.36 .307 5.08 .418 5.81 .539 6.54 .67

10 7.27 .8211 7.99 .9912 8.72 1.1813 9.44 1.3914 10.17 1.6115 10.89 1.8516 11.62 2.1017 12.35 2.3718 13.07 2.6619 13.80 2.9620 14.53 3.2821 15.25 3.6222 15.98 3.9723 16.70 4.3424 17.43 4.7225 18.16 5.1326 18.88 5.5427 19.60 5.9828 20.34 6.4329 21.06 6.9030 21.79 7.38

7/8” (.875 ID)


10 5.34 .4411 5.87 .5412 6.40 .6413 6.94 .7514 7.47 .8715 8.00 1.0016 8.54 1.1317 9.07 1.2818 9.60 1.4319 10.14 1.6020 10.67 1.7721 11.21 1.9522 11.74 2.1423 12.27 2.3424 12.81 2.5525 13.34 2.7726 13.87 2.9927 14.41 3.2328 14.94 3.4729 15.47 3.7230 16.01 3.9831 16.54 4.2532 17.08 4.5333 17.61 4.8234 18.14 5.1135 18.68 5.4236 19.21 5.7437 19.74 6.0638 20.28 6.3939 20.81 6.7340 21.34 7.08

Exit Loss Charts



Pipe Size

Fittings 1⁄4 3⁄8 1⁄2 3⁄4 1 11⁄4 11⁄2 2 21⁄2 3 4 5 6 8 10 12

ScrewedSteel 2.3 3.1 3.6 4.4 5.2 6.6 7.4 8.5 9.3 11.0 13.0

Regular C.I. 9.0 11.0

90° EllFlanged

Steel .92 1.2 1.6 2.1 2.4 3.1 3.6 4.4 5.9 7.3 8.9 12.0 14.0 17.0

C.I. 3.6 4.8 7.2 9.8 12.0 15.0

LongScrewed

Steel 1.5 2.0 2.2 2.3 2.7 3.2 3.4 3.6 3.6 4.0 4.6

Radius C.I. 3.3 3.7

90° EllFlanged

Steel 1.1 1.3 1.6 2.0 2.3 2.7 2.9 3.4 4.2 5.0 5.7 7.0 8.0 9.0

C.I. 2.8 3.4 4.7 5.7 6.8 7.8

ScrewedSteel .34 .52 .71 .92 1.3 1.7 2.1 2.7 3.2 4.0 5.5

Regular C.I. 3.3 4.5

45° EllFlanged

Steel .45 .59 .81 1.1 1.3 1.7 2.0 2.6 3.5 4.5 5.6 7.7 9.0 11.0

C.I. 2.1 2.9 4.5 6.3 8.1 9.7

ScrewedSteel .79 1.2 1.7 2.4 3.2 4.6 5.6 7.7 9.3 12.0 17.0

Tee-Line C.I. 9.9 14.0

FlowFlanged

Steel .69 .82 1.0 1.3 1.5 1.8 1.9 2.2 2.8 3.3 3.8 4.7 5.2 6.0

C.I. 1.9 2.2 2.1 3.9 4.6 5.2

Tee-Screwed

Steel 2.4 3.5 4.2 5.3 6.6 8.7 9.9 12.0 13.0 17.0 21.0

Branch C.I. 14.0 17.0

FlowFlanged

Steel 2.0 2.6 3.3 4.4 5.2 6.6 7.5 9.4 12.0 15.0 18.0 24.0 30.0 34.0

C.I. 7.7 10.0 15.0 20.0 25.0 30.0

ScrewedSteel 2.3 3.1 3.6 4.4 5.2 6.6 7.4 8.5 9.3 11.0 13.0

180° C.I. 9.0 11.0

Return Regular Steel .92 1.2 1.6 2.1 2.4 3.1 3.6 4.4 5.9 7.3 8.9 12.0 14.0 17.0

Bend Flanged C.I. 3.6 4.8 7.2 9.8 12.0 15.0

Long. Rad. Steel 1.1 1.3 1.6 2.0 2.3 2.7 2.9 3.4 4.2 5.0 5.7 7.0 8.0 9.0

Flanged C.I. 2.8 3.4 4.7 5.7 6.8 7.8

Friction Loss Created by Pipe FittingsThe friction created by fittings is expressed as the equivalent length of straight pipe. For example, the loss

through a 1” regular 90° Ell is equal to that created by 5.2 feet of straight 1” steel pipe. Determine total frictionby combining fitting loss with pipe loss.

Equivalent Length of Straight Pipe for Various Fittings.Turbulent Flow Only.



Pipe Size

Fittings 1⁄4 3⁄8 1⁄2 3⁄4 1 11⁄4 11⁄2 2 21⁄2 3 4 5 6 8 10 12

ScrewedSteel 21.0 22.0 22.0 24.0 29.0 37.0 42.0 54.0 62.0 79.0 110.0

Globe C.I. 65.0 86.0

ValveFlanged

Steel 38.0 40.0 45.0 54.0 59.0 70.0 77.0 94.0 120.0 150.0 190.0 260.0 310.0 390.0

C.I. 77.0 99.0 150.0 210.0 270.0 330.0

ScrewedSteel .32 .45 .56 .67 .84 1.1 1.2 1.5 1.7 1.9 2.5

Gate C.I. 1.6 2.0

ValveFlanged

Steel 2.6 2.7 2.8 2.9 3.1 3.2 3.2 3.2 3.2

C.I. 2.3 2.4 2.6 2.7 2.8 .29

ScrewedSteel 12.8 15.0 15.0 15.0 17.0 18.0 18.0 18.0 18.0 18.0 18.0

Angle C.I. 15.0 15.0

ValveFlanged

Steel 15.0 15.0 17.0 18.0 18.0 21.0 22.0 28.0 38.0 50.0 63.0 90.0 120.0 140.0

C.I. 23.0 31.0 52.0 74.0 98.0 120.0

SwingScrewed

Steel 7.2 7.3 8.0 8.8 11.0 13.0 15.0 19.0 22.0 27.0 38.0

Check C.I. 22.0 31.0

ValveFlanged

Steel 3.8 5.3 7.2 10.0 12.0 17.0 21.0 27.0 38.0 50.0 63.0 90.0 120.0 140.0

C.I. 22.0 31.0 52.0 74.0 98.0 120.0

CouplingScrewed

Steel .14 .18 .21 .24 .29 .36 .39 .45 .47 .53 .65

or Union C.I. .44 .52

Bell Mouth Steel .04 .07 .10 .13 .18 .26 .31 .43 .52 .67 .95 1.3 1.6 2.3 2.9 3.5

Inlet C.I. .55 .77 1.3 1.9 2.4 3.0

Square Steel .44 .68 .96 1.3 1.8 2.6 3.1 4.3 5.2 6.7 9.5 13.0 16.0 23.0 29.0 35.0

Mouth Inlet C.I. 5.5 7.7 13.0 19.0 24.0 30.0

Re-Entrapment Steel .88 1.4 1.9 2.6 3.6 5.1 6.2 8.5 10.0 13.0 19.0 25.0 32.0 45.0 58.0 70.0

Pipe C.I. 11.0 15.0 26.0 37.0 49.0 61.0

Sudden

Enlargement

Friction Loss Created by Pipe FittingsThe friction created by fittings is expressed as the equivalent length of straight pipe. For example, the loss

through a 1” regular 90° Ell is equal to that created by 5.2 feet of straight 1” steel pipe. Determine total frictionby combining fitting loss with pipe loss.

Equivalent Length of Straight Pipe for Various Fittings.Turbulent Flow Only.

b = (V1 - V2)

2

Feet of Fluid; if V2 = 0 b = V1

2

Feet of Fluid2g 2g



Calculating Turn Over RatesNew Pool or Spa – Divide the Pool or Spa gallons by thenumber of minutes the filter system is designed to operatein a single day.

Example:A 6 hour turn over is equal to 360 minutes.

A 8 hour turn over is equal to 480 minutes.

A 30 minute turn over is the divider.

50,000 gallon pool with a 6 hour turn over rate

50,000 / 360 = 139 gpm

25,000 gallon pool with an 8 hour turn over rate

25,000 / 480 = 52 gpm

1,000 gallon spa with a 30 minute turn over rate

1,000 / 30 = 33 gpm

Existing Pool or Spa – Determine the maximum flow ratefrom the existing pipe sizes (See Pipe Sizing Chart in thenext column).

Example:1-1/2” pipe = 44 gpm, 2” = 75 gpm

25,000 gallon pool with 1-1/2” pipe

25,000 / 1-1/2” Flow Rate x 60 = Turn Over Rate

25,000 / 44 x 60 = 9.5 hours

Filter SizingPool or Spa – Divide the pump gallons per minute by therecommended flow rate for the filter.

Example:D.E. = 1.5 gpm per sq. ft. of filter area.

80 gpm / 1.5 = 53

Sand = 15 gpm per sq. ft. of filter area.

74 gpm / 15 = 4.9

Cartridge = .375 gpm per sq. ft. of filter area.

50 gpm / .375 = 133

Pipe Sizing Chart - Schedule 40 PVCPipe Size 7 fps 8 fps 10 fps

3/4” 12 gpm 14 gpm 17 gpm1” 18 gpm 22 gpm 28 gpm

1-1/4” 33 gpm 37 gpm 47 gpm1-1/2” 44 gpm 52 gpm 62 gpm

2” 75 gpm 85 gpm 110 gpm2-1/2” 110 gpm 118 gpm 125 gpm

3” 160 gpm 185 gpm 235 gpm4” 275 gpm 310 gpm 395 gpm6” 540 gpm 725 gpm 850 gpm

Calculating Head Loss for an Existing Pool or Spa

Pressure Gauge x 2.31 = Head Loss plus

Vacuum Gauge x 1.13 = Head Loss equals

Total System Loss

Example:Pressure Gauge Reading = 20 lbs.Vacuum Gauge Reading = 10”

20 lbs. x 2.31 = 46 foot of head10” x 1.13 = 11 foot of head

Total System Loss = 57 foot of head

Modular Media Sizing

Size filters based on maximum design flow

Example:S8M150 - 450 sq. ft. = 125 gpm

500 gpm / 125 = 4 filters

500 gpm / 1800 sq. ft. = .28 flow rate

Calculating Filter Flow Rates

Divide the gallons per minute by the sq. footage of the filter.

Examples:125 gpm w/83 DE125 gpm / 83 = 1.5 gpm per sq. ft. of filter area

50 gpm w/ 3.4 Sand50 gpm / 3.4 = 15 gpm per sq. ft. of filter area

2 SECTION Pumps


Swimming Pool and SpaPumpsPumps used for swimming pools, spas, and water featuresare classified as centrifugal pumps. A centrifugal pumpderives its name from the principal known as centrifugalforce. A centrifugal pump, in its most simplified form, con-sists of two components. One component is stationary andserves as the housing. It is known as a volute. Inside thevolute is the rotating component known as the impeller. Ifthe motor is the “work horse” of the pump, the impeller isthe “cartwheel” that moves the water along.

The principal of operation can be demonstrated bywhirling a bucket full of water. In Figure 1, as the bucket isrotated, the water is held in the bucket by centrifugal force.(A) If we were to punch a hole in the bottom of the bucket,the water would be forced out, again by centrifugal force.(B) If we were to speed up the rotation of the bucket, thewater would exit with greater pressure. (C)

This same principal is performed by the impeller of thepump. As water enters the center or “eye” of the impeller,it is forced through the impeller vanes toward the outsideedge (Figure 2). The spinning, impelling action of these

vanes generates centrifugal force, propelling the water at agreater velocity (Figure 3)

This action imparts kinetic or velocity energy into thewater. As the water is propelled to the outer edge of theimpeller, there is a reduction in pressure at the eye of theimpeller, creating a partial “vacuum. (See Figure 4)

As we learned in the Hydraulic Section, atmospheric pres-sure is necessary for the pump to perform. The combina-tion of the atmospheric pressure on the surface of the waterand the vacuum at the eye of the impeller, causes the waterto flow in the “suction pipe” to the pump. (Figure 4)

Figure 2

CENTRIFUGAL FORCE

DISCHARGE

IMPELLER

IMPELLER EYE

WATER FLOW

ROTATION��

FLOW UNDERPRESSURE

ATMOSPHERICPRESSURE

14.7 LBS.

A

BC

Figure 3

Figure 1

Figure 4

2 SECTION Pumps


60

45

30

15

HEAD PRODUCED

03450RPM

1725RPM

60

45

30

15

GPM

03450RPM

1725RPM

The amount of pressure energy imparted into the water bythe impeller is determined in part by the size and design ofthe impeller. Figure 5 shows there are two types ofimpellers used in swimming pool, spa, and the water fea-ture pumps: semi-open impeller and closed impellers.

The semi-open impeller has the vanes exposed on the frontor receiving side. The back side of the vanes are closed by ashroud. (Top left of Figure 5)

The inner surface of the pump volute serves as the frontshroud of the impeller. The efficiency of this design isdetermined by the clearance between the front of theimpeller and the face of the volute surface. (Lower left ofFigure 5)

The clearance for a semi-open impeller can usually beadjusted by the set screws on the motor shaft or by the useof shims. This is considered a non-clogging impeller.

A closed impeller is designed to have two shrouds thatcompletely enclose the area of the impeller vane (Upperleft of Figure 5) These are called the front and rear shroud.The impeller design requires no adjustment, since thespace between the two shrouds is fixed.

The performance of an impeller is affected by another fac-tor. This factor is the speed of its rotation. The speed atwhich the impeller rotates affects its head and capacitycharacteristics. The GPM of pump impeller varies in directproportion to the change in its speed of rotation.

Example:The capacity of an impeller is 60 GPM at a rotatingspeed of 3450 RPM. Its capacity would drop to 30GPM if the speed of rotation was reduced to 1725RPM. (Lower right Figure 5)

The head or pressure produced by an impeller varies to thesquare of the change in its speed of rotation.

Example:If the speed of rotation of an impeller is reducedfrom 3450 RPM to 1725 RPM, or 50%, the headproduced by the impeller would change to thesquare of that percentage, or a 75% reduction.

If the head produced by an impeller is 60 ft., at aspeed of 3450 RPM, the head would drop to 15 ft.,if the rotating speed was reduced to 1725 RPM.

Note: The charts in Figure 5, Lower Right, are the basicprincipals of a 2 speed pump.

Figure 5

CLOSED IMPELLER

SEMI-OPENIMPELLER

IMPELLER

SETSCREWS

CLEARANCE

45 45

30 30

15 15

003450RPM

3450RPM

1725RPM

1725RPM

HEAD PRODUCEDGPM60 60

Flow

EYE

2 SECTION Pumps


Water flowing from a swimming pool, spa, or water featureusually will enter the pump through the hair and lint trap.(Figure 6 - A)

Inside the hair and lint trap is a strainer called the hair lintbasket. It is designed to collect trash and debris that couldclog the impeller. (Figure 6 - C)

Pumps that are installed with the filter on the suction sideusually do not need to have a hair lint trap. The filter actsas the trap, catching the trash and debris. This type ofinstallation is called a “Vacuum Systems” and is usuallyfound on portable spas, and some commercial pools.However, it is not uncommon to find a pump installedwithout the hair lint trap when used as a booster pump.When used in this manner, it’s source of water usuallycomes from another pump. (Figure 6 - B)

Water flows from the hair and lint trap to the impeller. Theimpeller discharges it directly in a vaned diffuser or into avolute, depending on the design of the pump.(Figure 6 - D)

A diffuser consists of a number of vanes which are setaround the impeller. As the water is discharged from theimpeller, its velocity is very high. As it flows through thediffuser, the vanes help to reduce the speed of flow. As aresult, the priming capabilities and the hydraulic efficien-cies of a pump are improved.

Other types of centrifugal pumps are designed to permitthe volute casing to fully encompass the impeller and flareout into the discharge opening. This allows a gradualreduction in the velocity of the water as it moves from theimpeller to the discharge port.

2978 0697

Figure 6D

HAIR &LINT TRAP

WATERFROMPOOL

WATERFROMFILTER

DIFFUSER

IMPELLER

IMPELLER

VELOCITYENERGY

PRESSUREENERGY

WATERFROMMAINPUMP

TRAPBASKETCOLLECTSDEBRIS

Figure 6C

Figure 6BFigure 6A

2 SECTION Pumps


10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

10

20

40

60

80

100

110

120

BA

Note: When comparing diffuser pumps and volute pumps,remember that each pump was designed with differentgoals. The diffuser pump can generally prime faster. Thevolute pump, on the other hand, works well where smallerpump bodies are needed such as portable spas and jettedbathtubs. The volute pump, designed with a semi-openimpeller can handle bodies of water that have debris prob-lems, such as pine needles, much better.

Most centrifugal pumps used on filtration systems are clas-sified as high head pumps. However, the real test of a cen-trifugal pump, is its “head vs. capacity” performance. Mostfilter manufactures recommend that the pressure in the fil-ter be allowed to rise as much as ten pounds per squareinch (psi) above the initial start-up pressure before the filteris cleaned. This rise in pressure affects an increase in thetotal system head which reduces the GPM of a centrifugalpump. A pressure rise in the filter of ten pounds psi trans-lates to an increase in total head of 23 ft.

1 lb. psi = 2.31 ft. of head

This rise in the resistance of the system affects the pump’sperformance.

Performance curve B in Figure 7 represents a typical 1 HPmedium head pump. Assume the filter media is clean. Thetotal system head is 60 ft. The capacity of pump B at 60 ft.of head is 75 GPM. An increase of 10 psi filter pressurewould raise the total system head to 83 ft. This increase of23 ft. of head causes the capacity of the pump to bereduced to 30 GPM, or a loss of approximately 60% flow.

Performance curve A in Figure 7 represents a typical highhead pump. At a total system head of 60 ft., the capacity ofthis pump is 75 GPM. At a total system head loss of 83 ft.,which represents a filter pressure increase of 10 psi, thecapacity of this pump declines to only 65 GPM, or a loss ofapproximately 15% flow.

It is clear that if you have a choice you would use a highhead pump on your filtration systems. If a medium headpump is used for a filtration system, it should be cleaned ata 5 lb. increase on the pressure gauge. The best applicationfor a medium head is for systems that have a constantpressure. Spa jets, water falls, fountains, etc. These applica-tions are generally sized at approximately 40 ft. of head.Pump B in Figure 7 will deliver over 90 GPM vs. Pump A,which will give you a little less than 80 GPM.

Figure 7

GPM“Both pumps are rated at 60 GPM at 60 Ft. of Head”

TDH

1 lb. = 2.31 ft. of headPump B Looses 45 GPM or 69% Pump A Looses 10 GPM or 15%

2 SECTION Pumps


1

2 3

4

78

9 14

13

12

18

17

16

15

56

1110

1898 0795

1. Match the numbers with the correct definition for eachof the component parts for the above pump.

____________ Hair and Lint Basket

____________ Impeller

____________ Volute and Trap Body

____________ Trap Handles

____________ Motor

____________ Trap Cover

____________ Stub Shaft Assembly

____________ Adapter Bracket and Seal Plate

____________ Trap “O” Ring

____________ Drain Plugs

____________ Ground Lug

____________ Shaft Seal

____________ Gasket

____________ Set Screws

2. Answer the following questions “Yes” or “No”.

A. This pump is considered a “Closed-Face ImpellerPump”.

■■ Yes ■■ No

B. The impeller used on this pump is considered a“Non-Clogging Impeller”.


C. Can an adjustment be made to the impeller setting?


D. When used as a self priming pump can you put a 90°elbow directly on the discharge of the pump?


Figure 8

2 SECTION Pumps


12 3

4

1920

8

5

6

9

9A

10

1114

15

16

121317

18

7

21

1831 0695

1. Match the numbers with the correct definition for eachof the component parts.

__________ Clamp

__________ Seal Plate

__________ Diffuser “O” Ring

__________ Motor

__________ Volute or Tank Body

__________ Ground Lug

__________ Impeller

__________ Water Slinger

__________ Shaft Seal

__________ Base

__________ Drain Plug

__________ Heat Sink

__________ Motor Pad

__________ Diffuser

__________ Pump “O” Ring

2. Answer the following questions “Yes” or “No”.

A. The impeller for this kind of pump can be adjusted.


B. This pump is designed with shaft seal heat protection.


C. The pump, as shown, is a self-priming pump.


Figure 9

2 SECTION Pumps


Pump Curves - Sizing PumpsThe four pumps in Figure 10 are typical high and mediumhead pumps. Answer the following questions based onthese pump curves:

1. Starting at 50 ft.. of head, which pump looses the mostflow during the 10 lb. rise in filter pressure?

A ■■ B ■■ C ■■ D ■■

2. Starting at 50 ft. of head, which pump looses the leastflow during the 10 lb. rise in filter pressure?

A ■■ B ■■ C ■■ D ■■

3. At 60 ft. of head, which pump delivers the most GPM?

A ■■ B ■■ C ■■ D ■■

4. If the filter is clean and the pressure gauge is reading 15lbs., and the vacuum gauge is reading 13 inches of mer-cury, how many GPM is pump C delivering?

5. If you had 7 spa jets, each delivering 15 GPM, at a headloss of 40 ft. Which pump would you select?

6. On a filtration system, you need 75 GPM. Which pumpwould you choose?

Figure 10DFigure 10C

Figure 10A Figure 10B

10 20 30 40 50 60 70 80 90 100 110 120

020406080

100120140160

GPM

TDH

10 20 30 40 50 60 70 80 90 100 110 120

020406080

100120140160

GPM

TDH

10 20 30 40 50 60 70 80 90 100 110 120

020406080

100120140160

GPM

TDH

10 20 30 40 50 60 70 80 90 100 110 120

020406080

100120140160

GPM

TDH

2 SECTION Pumps


Plumbing and Safety Tips:1. Don’t rely on the time clock being off when installing a

new or replacement pump. Time clock may kick on andelectrocute you.

2. When installing a pump more than 3 feet above waterlevel and more than 10 feet from the water’s edge, try totrench below the water level to a position directly belowthe suction of the pump. The vertical lift is still just 3feet. Most self priming pumps should not have a diffi-cult time priming at that lift.

3. Locating a pump in a low area can be dangerous. Makesure that it is in an area that has good drainage.Standing water can cause an electrical shock.

4. A loud pump does not always indicate a bearing prob-lem. Restrict the discharge of the pump and listen to seeif the pump quiets down. If it does, it’s cavitation, not abearing. Also, pushing down on the back of the motor,and/or lifting upon the back of the motor with a slightpressure may quiet the pump. If the noise diminishes,there is a possibility that the pump is hanging on theplumbing. Sometimes the pad may settle causing a levelinstallation to be out of plumb. With one end of thepump rigidly attached to the plumbing and the otherend a heavy motor, the motor shaft can can be bindingon the front bearing and/or seal.

5. Some motors use the motor case to dissipate the heatfrom the inside of the motor. A pump that is improperlysized, or installed with the incorrect wire size, or notventilated properly, and installed in direct sunlight cancause a burn if the hand is rested on the motor. Rule ofThumb: If you can leave your hand on the motor for afew seconds, it’s probably O.K. If you can’t leave yourhand on it for any period of time, you may have one ofthe above problems. However, placing your hand on themotor to determine if it is too hot is not a judgement ofwhether or not the motor is operating properly. It is anindication that something may be wrong.

Figure 12Figure 11

AIR INSYSTEM

AIR LOCK

ALLOW 4 TIMES THE PIPEDIAMETER BETWEEN THESUCTION PORT AND THEFIRST FITTING

KEEP SUCTION PIPESBELOW THE SUCTIONPORT OF THE PUMP

PLUMBING AND SAFETY TIPS

FITTING TOOCLOSE TO SUCTION OFPUMP

3 SECTION Motors


A.C. Power Supply

S N

Rotor

Stator

Swimming Pool and SpaMotorsMotors used with swimming pool, spa, and water featurepumps are designed to cover a wide range of applications,from fractional horsepower’s to 50 HP or more. Someapplications call for multiple speed or even variablespeeds. The applications often require the motor to operatecontinuously in the direct sunlight at air temperatures of120° F or higher, and in all types of weather.

The motor is one of the most important components of acentrifugal pump, yet, it is probably one of the mostabused. Improper wiring, ventilation, and environmentalfactors are just a few enemies of good motor operations.

PRINCIPLES OF OPERATIONThe electric motor is a device for converting electrical ener-gy into mechanical energy. The motor, in general, has a setof insulated wire windings: starting and running. Locatedon the stator, they are connected to an external powersource. The rotor consists of an iron bar and continuouswire loops. The magnetic field is established when currentsflow in these conductors in a narrow air gap between thestator and the rotor. The current flow in the windings pro-duces a rotating field that interacts with the rotor, causingthe rotor to move, thus converting electrical energy intomechanical energy (Fig.l).

There are several different types of motor designs used forpool, spa, and water feature pumps, listed in ascendingcost and efficiency:

1. Split Phase - Usually used in smaller circulation pumpswhich have very low starting torque requirements.Generally used in spa, jetted tub, above ground poolsand small water feature pumps. Some are used on thelower end of in-ground pool and jet pumps. This designhas a start winding and start switch, but no capacitors.

2. Capacitor Start - (Figure 2) - The most common type ofsingle phase pump motor. A starting capacitor is in thestart winding circuit to add faster, stronger startingtorque with the high current surge. (150 - 175% of thefull load).

Figure 1

3 SECTION Motors


E ENA I GJM

C CKB D N B M F H KL

2. Capacitor Start. (Cont.) - This gives the motor a startingcurrent lower than the split phase equivalent. The oper-ation is similar to the split phase in that there is a startswitch to take the start winding and capacitor out of thecircuit once the motor reaches 2/3 to 3/4 of full speed(Figure 2).

BASIC COMPONENT PARTS (Figure 2)(a) Main Frame (stator and coils)

(b) Rotor & Shaft Assembly

(c) Front and Rear Bearings

(d) Fan

(e) End Frames

(f) Capacitors (where used)

(g) Terminal Board

(h) Thermal Overload Protector

(i) Start Switch or Centrifugal Contactor

(j ) Governor

(k) Ground Terminal

(l) End Cover

(m) Stator

(n) Stator Windings or C

3. Capacitor Start/Capacitor Run (CSR)These are known as “energy-efficient” motors. Theyhave a starting capacitor as in Figure 2 above but havean additional capacitor The running capacitor helps tosmooth out the AC current flow and minimizes internalheat buildup, which is lost energy and higher energycosts. The running capacitor is combined with moremetal in the rotor and stator, CSR motors more effective-ly convert electrical energy to mechanical energy result-ing in less loss to heat. This is why CSR motors canoperate in higher ambient temperatures with less ther-mal overloading problems and deliver a longer servicelife in the windings of the stator, bearings, etc.

4. 3 PHASEThis is the simplest, most efficient design. It’s use is lim-ited to commercial and industrial applications sincethree phase power is not available in residential areas.There are 6 motor lead wires and no operating capaci-tors. They operate much more efficiently at lower ampsand watts. However, they require costly external relaysor magnetic contactors to be installed in the wiring tothe motor.

Figure 2

3 SECTION Motors


Motor NameplateEverything that you need to know about swimming pool,spa, and water feature pumps is on the nameplate. (SeeFigure 3). It is important that the pump specifier, dealerand installer understand each marking on a conventionalpump motor nameplate for safety, proper installation andservicing.

A – Most pump motors are dual voltage and therefore canbe run on either 115 or 220 volts. If 230 volts whereapplied to the motor when it is connected for 115 volts,chances are high that the motor will burn out immedi-ately. If 115 volts are applied to the motor when it isconnected to 220 volts, chances are the motor may runor not run, but will not come up to speed.

B – Thermal Overload Protector. This device is sensitive toheat and current flow. It acts as a breaker. This protec-tor automatically shuts off the motor if the internaltemperature becomes too hot.

The motor will restart automatically when the motorcools. The motor will continue to shut itself off untilthe problem is corrected or until the protector fails.Always replace the Thermal Protector with the samenumber stamped on the block. If there is a break in thecurrent flow the motor will not start or restart until theproblem is corrected.

C – The Canadian Standard Association (CSA) emblemindicates that the motor is constructed in accordancewith the standards established by CSA and therefore issatisfactory for installation in Canada. UL is theemblem for Underwriters Laboratory. UR is the ULrecognized component of a system, such as a compo-nent in a spa pac.

D – The motor model number identifies the motor typeparts that need to be obtained and determines theexact electrical characteristics, if there is a question onelectrical performance. It is vital to provide this num-ber whenever seeking a replacement motor or parts fora motor

E – Serial number - This code tells the month, year, andday the motor was manufactured.

Figure 4Figure 3

MAX.HP SF HP

1/2 1.30 .65

3/4 1.27 .95

1 1.25 1.25

1.5 1.10 1.65

2 1.10 2.20

2.5 1.04 2.60

LOW SERVICEFACTOR MOTOR

MAX.HP SF HP

1/3 1.95 .65

1/2 1.90 .95

3/4 1.65 1.25

1 1.65 1.65

1.5 1.47 2.20

2 1.30 2.60

HIGH SERVICEFACTOR MOTOR

L1

L2

B

A

BLACK

115VLINE

BLACKTRACER

L1

L2

B

A

BLACK

220VLINE

BLACKTRACER

A

UB CD E

F G

R S

M N

H I TJ K L

O P Q

CAUTIONDO NOT OPERATE MOTOR WITHOUT CONNECTING GROUND WIRE TO GREEN GROUNDING SCREW. DO NOT CONNECT TO A POWER SOURCE OTHER THAN THAT SPECIFIED ON NAME PLATE. COVER MUST BE REPLACED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS OR FATAL INJURY.

616231

616230-2

MET38ABN

C48J2DB11 SER. A89D

HP 1/2

HZ 60

SF 1.9

CONT.

PH 1 CODE L

MOTOR MOD.

115/230

8.4/4.2

VOLTS

TYPE C A. O. SMITH CORP.

AMPS

B AMB 50° C

10.8/5.4

3450RPM FR 56C

LLTHERMALLYPROTECTED

MAXLOAD

INSUL.CLASS

TIMERATING

SP

3 SECTION Motors


F – Voltage rating for the motor - Either 115 or 230 volts.Note the wiring terminal diagram for correct connec-tions for either voltage.

G – Nominal or “Advertised” HP of the motor.

H – The amps listed are for nominal HP and should not beused for sizing the wire or setting the circuit breakers.(See M, Max Load Amps).

I – Almost all residential installations are single phase(normal house current). Commercial pumps are often3-phase, with six wire leads coming out of the motor.

J – 3450 RPM is the standard speed for pump motors.1750 RPM is used in larger commercial pumps and in2 speed pumps for the slower speed and energy con-servation.

K – Motor frame size - This is important when a motor isbeing replaced. For example, a 48J frame is of a differ-ent dimension than a 56J. Frame size is determined bymeasuring the distance from the center of the motorshaft to the base of the motor mount, times 16.i.e. 3” x 16 = a 48 Frame.

L – Hertz (HZ) is the term for cycle frequency of alternat-ing current (AC). 60HZ (cycles) is the only frequencyused in the United States. 50HZ is found in manyother countries.

M – Maximum load amps designates the maximumamount of amperage drawn by a motor when it isoperating at its full load horsepower rating. Maximum

load amperage is IMPORTANT. It is the value towhich all circuit breakers, fuses, heaters and wire mustbe sized. Never size any of these components to anamperage value that is less than the maximum loadamperage drawn by the motor as designated on thedata plate. Any amperage measurement drawn by themotor above its max. load amps would be consideredan overload, which can have a variety of causes oreffects.

N – The service factor of an alternating current electricmotor, as defined by (NEMA) National ElectricalManufactures Association, is a multiplier which, whenapplied to the name plate HP rating, indicates themaximum safe operating HP at which the motor canbe loaded for continuous duty operation.

High and Low Service Factor (Figure 4) - An electric motormay be rated as either a 1 or a 1-1/2 HP. However, whenthe motor is rated as a 1-1/2 HP, its service factor wouldchange from 1.65 to 1.1. Both motors have the same fullload HP capacity, and the maximum load amperage forboth motors would be the same.

Figure 4Figure 3

MAX.HP SF HP

1/2 1.30 .65

3/4 1.27 .95

1 1.25 1.25

1.5 1.10 1.65

2 1.10 2.20

2.5 1.04 2.60

LOW SERVICEFACTOR MOTOR

MAX.HP SF HP

1/3 1.95 .65

1/2 1.90 .95

3/4 1.65 1.25

1 1.65 1.65

1.5 1.47 2.20

2 1.30 2.60

HIGH SERVICEFACTOR MOTOR

L1

L2

B

A

BLACK

115VLINE

BLACKTRACER

L1

L2

B

A

BLACK

220VLINE

BLACKTRACER

A

UB CD E

F G

R S

M N

H I TJ K L

O P Q


616231

616230-2

MET38ABN

C48J2DB11 SER. A89D

HP 1/2

HZ 60

SF 1.9

CONT.

PH 1 CODE L

MOTOR MOD.

115/230

8.4/4.2

VOLTS


AMPS

B AMB 50° C

10.8/5.4

3450RPM FR 56C


MAXLOAD

INSUL.CLASS

TIMERATING

SP

3 SECTION Motors


Black leadto terminal

L1

White leadw/blacktracer to

terminal "A" A

L1

O – This is the insulation class as designated by NEMA. Itdesignates the temperature it can withstand with outbeing damaged.

P – This is the maximum ambient temperature of the sur-roundings that the motor should be subjected to. 40° C = 104° F 50° C = 124° F

Q – This means the motor is suitable for operation on acontinuous basis at its rated load without a break.

R – This is the electrical type, with most motors beingcapacitor start.

S – Identifies the manufacturer. Consult their instructionmanual for proper installation and operation.

T – The code is a letter designation for locked rotor kVAper HP as measured at full voltage and rated frequency.

U – This symbol designates UL component recognition. ULstandard 1081 covers swimming pool/spa pumps.

Exercise:Answer the next 3 questions using the sample DataPlate in Figure 3.

1. What size circuit breaker would you use if thispump was connected to 115 volts?________

2. What is the Max Load HP of thispump?________

3. Using the Charts and Tables, pages 58 & 59,what size wire would you use for a 200 ft. distance?

115 volt________ , 230 volt________ , 230 volt 3-phase________.

4. Is the pump in Figure 5 wired for 115 volt or230 volts?________

5. Using the Charts and Tables, Page 57, completethe following chart.

Note: cost of electricity is 15 cents per kilowatthour.

Figure 5Figure 3

Cost 8Motor Per Hour

HP Hour Day Week Month Year

1/2

3/4

1

1-1/2

2

3

L1

L2

B

A

BLACK

115VLINE

BLACKTRACER

L1

L2

B

A

BLACK

220VLINE

BLACKTRACER

A

UB CD E

F G

R S

M N

H I TJ K L

O P Q


616231

616230-2

MET38ABN

C48J2DB11 SER. A89D

HP 1/2

HZ 60

SF 1.9

CONT.

PH 1 CODE L

MOTOR MOD.

115/230

8.4/4.2

VOLTS


AMPS

B AMB 50° C

10.8/5.4

3450RPM FR 56C


MAXLOAD

INSUL.CLASS

TIMERATING

SP

3 SECTION Motors


Electrical & Safety Tips:1. Figure 6 - Never assume that the power is off. A time

clock could “CLICK ON” and electrocute you. Alwaysshut off the main power at the master breaker beforeworking on motor.

2. Ventilation - Motors need air circulating to keep thetemperature down. A rule of thumb is to provide at least1 square foot of vent space at the top of an equipmentroom and the bottom of the equipment room for eachhorsepower of the motor for adequate ventilation. Thisis in addition to other types of equipment that requireventilation, such as a heater.

3. Use a ventilated motor cover to protect the motor fromthe elements, such as rain and the sun.

4. Don’t use the pool while electrical devices are in thewater. Pool drainers may have a frayed electrical cord.As an extra precaution, plug the electrical device into anoutlet that has a GFCI protector.

5. Chemical Storage - Keeping chlorine, acid and otherchemicals in close proximity to the pool equipment willshorten the life of almost everything metal in the area.

6. Improperly sized and/or wired pumps may have veryhot motor casings. Over-loaded, under-wired, and poor-ly-ventilated motors can have very hot casings. Hotenough to burn your hand.

7. Refer to the motor wiring diagram before making anyelectrical connections. Always connect the ground wirefirst.

Figure 6

ELECTRICAL AND SAFETY TIPS

3 SECTION Motors


ELECTRIC POWER

AC = Alternating current power

DC = Direct current

E = Volts = Electrical pressure (similar to head)

I = Amperes = Electrical current (similar to rate of flow)

W = Watts = Electrical power (similar to head capacity)

kW = Kilowatts = 1000 watts

Apparent Power = Volts x amperes = Voltamperes

Apparent Power - EI

Useful Power W = EI x P.F.

Power factor = ratio of useful power to apparent power

Power factor = PF = W

EI

kW Hr. = Kilowatt hour

Single phase power W = E x I x PF

3 Phase Power W = 1.73 x I x PF

Where E = Average voltage between phases

I = Average current in each phase

HORSEPOWER

1 HP equals. . ..746 kilowatts or 746 watts33,000 ft . lbs. per minute

550 ft. lbs. per second

WATER HORSEPOWER

=GPM x 8.33 x Head

=GPM x Head

33,000 3960

GPM = Gallon per Minute8.33 = Pounds of Water per Gallon33,000 = Ft.-lb. per Minute in one HP

LABORATORY BHP

=Head x GPM x Sp. Gr.

3960 x Eff.

GPM = Gallon per MinuteHead = Laboratory Head (inc. column loss)Eff. = Pump Only Efficiency

MOTOR INPUT HP

=Laboratory BHP

Motor Eff.

Total BHP from aboveMotor Eff. from Manufacturer

UNIT EFFICIENCY

=Water Horsepower

Motor Input Horsepower

Water Horsepower from aboveInput Horsepower from above

*Average Kilowatts Input *Average Kilowatts Inputor Cost per Hour Based on or Cost per Hour Based on

Motor 1 Cent per Kilowatt Hr. Motor 1 Cent per Kilowatt Hr.HP 1-Phase 3-Phase HP 3-Phase

1⁄4 .305 –– 15 12.81⁄3 .408 –– 20 16.91⁄2 .535 .520 25 20.83⁄4 .760 .768 30 25.01 1.00 .960 40 33.2

11⁄2 1.500 1.41 50 41.32 2.000 1.82 60 49.53 2.95 2.70 75 61.55 4.65 4.50 100 81.5

71⁄2 6.90 6.75 125 10210 9.30 9.00 150 122

200 162

Approximate Cost of Operating Electric Motors

*For any other rate multiply by the rate:

Example: To determine cost of operating a 3/4 HP single phase motor at 3 cents per kilowatt hour multiply .760 X 3 = 2.280 cents or approximately 21⁄4 cents per hour.

3 SECTION Motors


AWG Wire Size

Amps 14 12 10 8 6 4 2 0

2 595 946 14793 397 630 9864 298 470 740 1161 18085 238 378 592 926 14476 198 315 493 774 1206 18427 170 270 423 663 1033 15798 149 236 370 581 904 13819 132 210 329 516 804 1228 187110 119 189 296 464 723 1105 168412 99 158 247 387 603 921 140314 135 211 332 517 789 1203 162216 118 185 290 452 691 1052 142018 164 258 402 614 935 120120 148 232 362 553 842 113622 134 21124 123 194

Single Phase Wire Size Selection Charts

Maximum Distance of Wire Run.

115 Volts – 1 Phase

AWG Wire Size

Amps 14 12 10 8 6 4 2 0

2 1035 16443 690 1096 17154 518 822 12875 414 658 1029 16156 345 548 858 1346 20977 296 470 735 1154 17978 259 411 643 1010 1573 24039 230 365 572 897 1398 213610 207 329 515 808 1258 1922 292812 173 274 429 673 1048 1602 244014 235 368 577 899 1373 2091 282116 206 322 505 786 1201 1830 246918 286 449 699 1068 1627 219420 257 404 629 961 1464 197522 234 367 572 874 1331 179524 214 337 524 801 1220 164626 311 484 739 1126 151928 288 449 686 1046 141130 269 419 641 976 131735 231 359 549 837 112940 315 481 732 98845 280 427 651 87850 252 384 586 79055 349 532 71860 320 488 658



AWG Wire Size

Amps 14 12 10 8 6 4 2 0

2 1190 18913 794 12614 595 946 14795 476 756 1184 18586 397 630 986 1548 24117 340 540 845 1327 20678 293 473 740 1161 1808 27639 265 420 658 1032 1607 245610 238 376 592 929 1447 2210 336712 198 315 493 774 1206 1842 280614 270 423 663 1033 1579 2405 324516 236 370 581 904 1381 2105 283918 329 516 804 1228 1871 252420 296 464 723 1105 1684 227122 269 422 658 1005 1531 206524 247 387 603 921 1403 189326 357 556 850 1295 174728 332 517 789 1203 162230 310 482 737 1122 151435 265 413 632 962 129840 362 553 842 113645 321 491 748 100950 239 442 673 909



3 SECTION Motors


00

10

20

30

40

50

60

70

80

90

100

10 20 30 40 50 60 70 80 90 100

TDH

GPM

PLUMBING SYSTEM READINGSPump Filter Energy Flow

Pipe Pipe Vacuum Pressure Pressure Used Meter SystemSuction Discharge x 1.13 x 2.31 x 2.31 AMPS GPM Head Loss

FPS FPS HL HL HL TDH










FPS = Feet Per SecondHL = Head LossTDH = Total Dynamic Head

Pump Curve Graph

3 SECTION Motors


AIR INSYSTEM

FITTING TOO CLOSE TOSUCTION OF PUMP

ALLOW 4 TIMES THE PIPE DIAMETERBETWEEN THE SUCTION PORT AND THEFIRST FITTING

AIR LOCK

KEEP SUCTION PIPES BELOW THESUCTION PORT OF THE PUMP

TYPE OF PIPE

STAINLESS STEELOR PVC

COPPER

GALVANIZED

FLEX PIPE

20% MORE RESTRICTIVE



COMPARED TOPVC

ATMOSPHERIC PRESSURE

5,000'

4,000'

3,000'

2,000'

1,000'

SEA LEVEL

A SELF PRIMINGPUMP WILLLOOSE 10% OFITS ABILITY TOLIFT WATER FOREVERY 1,000'OF ELEVATION

PUMP CANLIFT WATER

PUMP CANLIFT WATER

5'

10'

ATMOSPHERIC PRESSURE AT SEA LEVEL = 14.7 lbs.ATMOSPHERIC PRESSURE AT 5,000 FEET = 12.0 lbs.

REDUCE RESISTANCE

2 - 45° ELLSSWEEP90° ELL90° ELL

50% LESSRESISTANCE

40% LESSRESISTANCE

MULTIPLE PIPES

3"

1-1/2" A 1-1/2" PIPECAN ONLYHANDLE 1/4THE FLOW OFA 3" PIPE

USE THE PIPE SIZING CHARTS TO SIZEMULTIPLE PIPES TO REPLACE A SINGLE PIPE

1-1/2" = 44 GPM 3" = 160 GPM

1/4 th

Plumbing Tips

• Long plumbing runs – Increase pipe size, don’t increase pump horsepower.• Restrict flow at the top of a waterfall, not at the pump.• Balance the flow by looping the plumbing or tying in at the center and branching an equal distance in each direction.

4 SECTION Filtration


Swimming Pool, Spa, &Water Feature Filtration:Filters used for swimming pools, spas and water featuresare designed to physically remove suspended particlesfrom the water. The water containing the solid dirt parti-cles passes through a filter medium. The medium retainsthe particles while the “filtered water” passes through.

Filter Media:Generally, three types of filter media are used for removingthe suspended dirt particles from water in a swimmingpool, spa, or water feature.

1. Diatomaceous Earth (D.E.)

2. Silica Sand

3. Cartridge or Fiber

“Which Filter is Best”This is an often asked question. All three of the filters areused in almost every kind of application. Filter selection isusually made because of the preferences of the specifier, ordesigner. “They specify what they like and have experiencewith”. The best advice is to leave your options open andlook at other types of filtration. Another type of filter maydo the job better than what you normally use.

Exercise:Complete the left side of the chart below.

Figure 1 Figure 2 Figure 3

D.E. 2 4 4 4 4

SAND 3 3 2 1 1

CARTRIDGE 4 1 3 3 3

MEGA. CART. 1 2 1 2 2

1. Best 2. Very Good 3. Good 4. O.K.

Micr

on

Rem

oval

Dirt

Load

ing

Cost

New Cy

cle

Time

Main

tenan

ce

Time

Main

tenan

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Cost

Repl

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Cost

(Inter

nals) Applications

Water FishPool Spa Feature Ponds Ponds

UNFILTERED

UNFILTEREDFILTEREDFILTERED

FILTERED

UNFILTERED

SANDDIATOMATEOUSEARTH

CARTRIDGE

4 SECTION Filtration


NOT TO SCALE

Grids

Endhub

Drive hubassembly

Spacer

Grid support

GridsCollectionmanifold

Grid support

Connectorrods

Internal air bleed

Manifold

Diatomaceous Earth Filters:Diatomaceous earth filters use, as a medium, the tiny skele-ton remains of an animal called a “diatom”. Each tiny fossilis porous and contains m

sta-rite basic training manual...circulation system p ool & spa basic training 1 s4247 3 5 swim. .....

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